Preparation of Starry Foam Aluminum Conductive Coating

Preparation of Starry Foam Aluminum Conductive Coating by Cheersonic Ultrasonic Spraying Equipment and Analysis of Application Technology of Lithium Sodium Electrolyte

In the process of iterative upgrading of new energy battery technology, the performance of electrode current collectors and functional coatings directly determines the breakthrough space for battery energy density, cycle life, and safety stability. Star foam aluminum, with its three-dimensional interconnected porous structure, ultra-high specific surface area and excellent conductivity and thermal conductivity, has become the core basic foil material of “no or few negative electrodes technology” for sodium and lithium batteries. The ultrasonic spraying equipment is the key process equipment to realize the high-precision and high consistency preparation of Star foam aluminum conductive coating, which provides a solid technical support for the leap of battery performance.

Compared to traditional spraying processes, ultrasonic spraying equipment uses high-frequency ultrasonic vibration atomization technology to atomize conductive slurries (such as porous carbon systems, VGCF, whisker carbon tubes, etc.) into uniform and fine micrometer sized droplets. During the spraying process, the liquid drops accurately deposit on the inner wall and surface of the channel of Starry foam aluminum in the way of low pressure and low flow rate, forming a conductive primer with strong adhesion. This non-contact spraying method can perfectly adapt to the porous structure of Star foam aluminum, avoid the problems of pore blockage and uneven coating thickness caused by high-pressure spraying, and effectively reduce the waste of slurry and improve the utilization rate of materials.

The Star foam aluminum conductive coating prepared by ultrasonic spraying equipment has two core performance advantages, which directly enables the improvement of battery cycle stability. The first is the high bonding force. The coating formed by ultrasonic atomization and the foam aluminum substrate are combined at the molecular level, and the coating is not easy to crack and fall off, which can effectively solve the problem of active material falling off caused by electrode volume expansion and contraction during the charging and discharging cycle of the traditional coating, and greatly extend the cycle life of the battery. The second is the low impedance characteristic. The uniformly covered conductive coating opens up the electron transmission path in the holes of the starry sky foam aluminum. In combination with the three-dimensional porous structure of the foam aluminum itself, it significantly increases the contact area between the electrode and the electrolyte, reduces the charge transmission resistance, and improves the battery’s rate performance and charge discharge efficiency.

The Star foam aluminum conductive coating prepared by ultrasonic spraying plays an irreplaceable role in the research and development of “no or few negative electrode technology” for sodium and lithium batteries. This technology supports a stepped coating design and can spray porous carbon based materials with different ratios in layers according to the performance requirements of battery electrodes VGCF、 Whisker carbon nanotubes and other materials. This stepped structure can optimize the ion transport kinetics at the electrode interface, regulate the deposition behavior of lithium/sodium metal, suppress dendrite growth, and reduce the safety hazards of the battery. At the same time, based on the synergistic effect of the high porosity of Star foam aluminum and the conductive coating, the battery can save the traditional negative electrode material, or significantly reduce the amount of negative electrode, achieving a significant increase in battery energy density, providing a new technical path for the research and development of high endurance new energy vehicles and high-capacity energy storage equipment.

From the perspective of industrial application prospects, the combination technology of ultrasonic spraying equipment and Star foam aluminum conductive coating is gradually becoming the core process scheme in the field of new energy batteries. In the field of power batteries, this technology can help car companies break through the bottleneck of range; In the field of energy storage batteries, it can improve the cycle life and charging and discharging efficiency of batteries, and reduce the full lifecycle cost of energy storage systems. With the acceleration of commercialization of sodium electricity technology, Star foam aluminum conductive coating is expected to become one of the key materials for sodium electricity industrialization and promote the high-quality development of new energy storage industry by virtue of its advantages of strong adaptability and stable performance.

In the future, with the continuous upgrading of ultrasonic spraying technology and the continuous optimization of conductive paste formula, the performance of Star foam aluminum conductive coating will further break through, providing broader innovation space for the iteration of new energy battery technology.

About Cheersonic

Cheersonic is the leading developer and manufacturer of ultrasonic coating systems for applying precise, thin film coatings to protect, strengthen or smooth surfaces on parts and components for the microelectronics/electronics, alternative energy, medical and industrial markets, including specialized glass applications in construction and automotive.

Our coating solutions are environmentally-friendly, efficient and highly reliable, and enable dramatic reductions in overspray, savings in raw material, water and energy usage and provide improved process repeatability, transfer efficiency, high uniformity and reduced emissions.